Staple cartridge with shipping wedge

ABSTRACT

An end effector usable with a surgical instrument includes a first jaw pivotably coupled to a second jaw. The first jaw includes staple forming depressions. A staple cartridge is releasably attachable to a channel of the second jaw. A plurality of staples is disposed in the staple cartridge. A shipping wedge is releasably attached to the staple cartridge. The shipping wedge maintains the staples in their respective retention slots and is usable to separate the staple cartridge from the channel of the second jaw.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of and priority to U.S. ProvisionalPatent Application No. 61/774,942, filed Mar. 8, 2013, the entiredisclosure of which is incorporated by reference herein.

BACKGROUND

1. Technical Field

The present disclosure relates to a staple cartridge for use with asurgical instrument. More particularly, the present disclosure relates astaple cartridge with a shipping wedge for maintaining a plurality ofsurgical fasteners in the staple cartridge and for separating the staplecartridge from a cartridge housing of the surgical instrument.

2. Background of Related Art

Surgical devices for applying surgical fasteners to tissue are wellknown. Endoscopic surgical devices for applying staples, clips or otherfasteners include a handle assembly for actuating the device, anendoscopic shaft, and a tool assembly at the distal end of theendoscopic shaft. Certain of these devices are designed for use withreplaceable loading units housing the staples or fasteners. For example,in using an endoscopic linear stapler, the user may select a loadingunit with staples of a selected size and arranged in one or more linesof staples having a selected staple line length. After firing, the usermay remove the loading unit, select another loading unit of the same ordifferent size, and fire staples from the instrument again. Endoscopicsurgical staplers having four lines of staples, arranged in pairs oneither side of a cut line, are known.

Loading units in the form of replaceable cartridges are known. Bycontrast, other devices have loading units having a tool assembly,including a cartridge, anvil, drive assembly and knife are known. Suchloading units have the benefit of providing a new knife with eachloading of the loading unit.

Various surgical procedures are performed with surgical instrumentshaving disposable or replaceable loading units. These loading unitsgenerally include a movable part or parts positioned to engage a drivemember of a surgical instrument. If the moving part is not properlyretained in position prior to and during attachment of the loading unitto a surgical instrument, the loading unit may not properly engage thesurgical instrument and, thus, may not function properly. Some surgicalinstruments are provided with automatic locking systems which blockmovement of the components of the tool assembly prior to attachment to asurgical instrument and allow free movement of the movable parts of thetool assembly once the loading unit has been properly positioned on thesurgical instrument.

SUMMARY

An end effector having first and second jaws is disclosed herein. Thefirst jaw includes staple forming depressions and is pivotable withrespect to the second jaw. The second jaw has a generally U-shapedchannel defined by opposing sidewalls and a bottom surface. A pair ofopposed recesses are located in a distal portion of the channel.Additionally, each of the opposed sidewalls includes a slot in a distalportion of the channel. An extension extends distally from the distalend of the second jaw and the extension includes a sloped surface.

A staple cartridge is releasably coupled to the second jaw and thestaple cartridge includes opposed sidewalls. Each sidewall has a railthat extends along the sidewall and is parallel to a longitudinal axisof the staple cartridge. Each rail also protrudes outwardly from itsrespective sidewall. The staple cartridge includes a plurality of tissuecontacting surfaces that are arranged in a stepped configuration. Eachtissue contacting surface includes a plurality of retention slots havingopenings extending through the respective tissue contacting surfaces.The retention slots include a corresponding number of staples andpushers. The pushers slidably interact with a sled that is translatablebetween a proximal end of the staple cartridge and a distal end of thestaple cartridge in response to actuation of a drive mechanism in asurgical instrument that is coupled to the end effector. A knife slotextends along a central longitudinal axis of the staple cartridge and isconfigured to allow proximal and distal translation of a knife. A pairof opposing protrusions is located near the distal end of the staplecartridge and releasably engages the recesses of the channel.Additionally, the staple cartridge includes opposed tabs near the distalend that are insertable into the notches of the staple cartridge foraligning the staple cartridge within the channel of the second jaw. Anose of the staple cartridge includes a recess that is aligned with thesloped surface of the second jaw when the staple cartridge is fullyseated in the channel. A gap is defined by the recess of the nose andthe sloped surface.

A shipping wedge is releasably attachable to the staple cartridge formaintaining the staples in their respective retention slots. Theshipping wedge includes opposing top and bottom surfaces with a tongueextending from a distal end of the shipping wedge. The tongue includes atapered surface and a distal tip. A plurality of tabs extends from thebottom surface of the shipping wedge and a central keel is attached tothe bottom surface of the shipping wedge. Each tab has an outer surface,an inner surface, a planar bottom surface, and an inwardly extendingprotrusion. Each tab is flexibly and resiliently attached to theshipping wedge and releasably engages the rails of the staple cartridge.

According to one aspect of the present disclosure, an end effector for asurgical instrument includes a first jaw having a channel, a second jawpivotably coupled to the first jaw, a staple cartridge positioned in thechannel, and a shipping wedge releasably attached to the staplecartridge. The shipping wedge having a tongue extending from one endthereof, the tongue engageable with a distal portion of the staplecartridge and a distal portion of the first jaw such that manipulatingthe shipping wedge separates the staple cartridge from the first jaw.The tongue may have a tapered configuration and the first jaw may have arecess for receiving the tongue. The first jaw may have a generallyU-shaped configuration with opposing sidewalls and each sidewall mayinclude a rib extending along a portion of its length. The shippingwedge may have a plurality of tabs and each tab may be configured forreleasably engaging the ribs of the second jaw. The shipping wedge maymaintain a uniform distance between the first and second jaws. Theshipping wedge may have a keel that is disposed in a channel of thestaple cartridge. The keel may align the shipping wedge and the staplecartridge. The keel may inhibit translation of an actuation memberthrough the channel. The keel may also have surface features that attachthe shipping wedge to the staple cartridge. The shipping wedge maymaintain surgical fasteners in their respective retention slots. Thestaple cartridge may have opposed sidewalls and each sidewall mayinclude a knob extending therefrom such that the knobs may be receivedin recesses formed in the distal portion of the first jaw. Theengagement of the knobs and the recesses may maintain the staplecartridge in the first jaw. A gap may be defined between the distalportion of the staple cartridge and the distal portion of the second jawmember such that the tongue of the shipping wedge may be inserted intothe gap.

In certain embodiments, a sloped surface is formed at the distal end ofthe second jaw member. The sloped surface can extend from an externalbottom surface of the second jaw member and leads angularly to aninterior surface of the second jaw member.

In any of the embodiments disclosed herein, the shipping wedge can havea stepped shape.

In a further aspect of the present disclosure, a method of removing astaple cartridge from a stapling instrument includes the steps ofseparating a shipping wedge from a staple cartridge, the staplecartridge being part of a cartridge assembly including a plurality ofstaples and staple pushers; inserting a distal end of the shipping wedgeinto a gap between the staple cartridge and the stapling instrument; andmanipulating the shipping wedge to separate the staple cartridge fromthe stapling instrument.

The stapling instrument can include a jaw and the gap can be definedbetween the staple cartridge and the jaw, the distal end of the shippingwedge being inserted in the gap between the jaw and the staplecartridge. The distal end of the shipping wedge can include a tongue.The tongue of the shipping wedge can be inserted into the gap.

In another aspect, a method of replacing a staple cartridge of astapling instrument includes separating a shipping wedge from a staplecartridge, the staple cartridge being part of a cartridge assemblyincluding a plurality of staples and staple pushers; inserting a distalend of the shipping wedge into a gap between the staple cartridge andthe stapling instrument; manipulating the shipping wedge to separate thestaple cartridge from the stapling instrument; and replacing the staplecartridge with an unfired staple cartridge.

In the method, the unfired staple cartridge can have an actuation memberwith a knife.

DESCRIPTION OF THE DRAWINGS

Various embodiments of the presently disclosed shipping wedge aredisclosed herein with reference to the drawings, wherein:

FIG. 1 is a side perspective view of a cartridge assembly including astaple cartridge and a shipping wedge according to an embodiment of thepresent disclosure;

FIG. 2 is a bottom perspective view of the cartridge assembly of FIG. 1;

FIG. 3 is an enlarged view of the area of detail “3” of FIG. 2;

FIG. 4 is a side cross-sectional view of the cartridge assembly of FIG.1 taken along section line 4-4;

FIG. 5 is an exploded perspective view of the cartridge assembly of FIG.1 with parts separated;

FIG. 6 is a bottom perspective view of the shipping wedge of FIG. 1;

FIGS. 6A and 6B are bottom perspective views of other shipping wedgesaccording to embodiments of the present disclosure;

FIG. 7 is an end cross-sectional view of the cartridge assembly of FIG.1 taken along section line 7-7;

FIG. 8 is an end cross-sectional view of the cartridge assembly of FIG.1 taken along section line 8-8;

FIG. 9 is an end cross-sectional view of the cartridge assembly of FIG.1 taken along section line 9-9;

FIG. 10 is a perspective view of an end effector with the cartridgeassembly of FIG. 1 showing the shipping wedge used as a release tool forthe staple cartridge;

FIG. 11 is an enlarged view of the area of detail “11” of FIG. 2;

FIG. 12 is an enlarged view of the area of detail “12” of FIG. 21;

FIG. 13 is an end cross-sectional view of the end effector of FIG. 10taken along section line 13-13;

FIG. 14 is a bottom perspective view of the shipping wedge and thestaple cartridge prior to separating the staple cartridge from the endeffector;

FIG. 15 is an enlarged view of the area of detail “15” of FIG. 14;

FIG. 16 is an enlarged view of the area of detail “15” of FIG. 14showing the shipping wedge engaged with the staple cartridge;

FIG. 17 is a side cross-sectional view of the end effector and shippingwedge of FIG. 10 taken along section line 17-17;

FIG. 18 is an enlarged view of the area of detail “18” of FIG. 17;

FIG. 19 is an enlarged view of the end effector and shipping wedge ofFIG. 17 showing the shipping wedge separating the staple cartridge fromthe end effector;

FIG. 20 is an enlarged view of the area of detail “20” of FIG. 19;

FIG. 21 is a perspective view of the end effector and the staplecartridge assembly without the shipping wedge prior to attaching thestaple cartridge assembly to the end effector; and

FIG. 22 is a perspective view of a manually operated surgical staplingdevice according to certain embodiments, that may be used in endoscopicprocedures; and

FIG. 23 is perspective view of a powered or motorized surgical deviceaccording to certain embodiments, that may be used in endoscopicprocedures

DETAILED DESCRIPTION OF THE EMBODIMENTS

Embodiments of the presently disclosed cartridge assembly with a staplecartridge and a shipping wedge will now be described in detail withreference to the drawings wherein like numerals designate identical orcorresponding elements in each of the several views. As is common in theart, the term “proximal” refers to that part or component closer to theuser or operator, while the term “distal” refers to that part orcomponent farther away from the user or operator.

The presently disclosed cartridge assembly with a staple cartridge and ashipping wedge is usable with endoscopic surgical stapling devicescapable of accepting replaceable loading units. An example of such adevice is disclosed in U.S. Pat. No. 7,753,246 the entire contents ofwhich are hereby incorporated by reference.

An end effector 100 (FIGS. 10 and 21) includes opposing first and secondjaws 20, 40 that are pivotably coupled to one another. The end effector100 can be provided at the distal end of an endoscopic shaft 30 as partof a surgical stapling device, or can form part of a removable anddisposable loading unit 32 for a surgical stapling device 10, 10′. FIG.22 shows a manually operated surgical stapling device 10 that may beused in endoscopic procedures. FIG. 23 shows a powered or motorizedsurgical stapling device 10′ that may be used in endoscopic procedures.Other devices are contemplated, such as other manually operated devicesor robotically operated devices.

The jaws 20, 40 of the end effector 100 are configured for movementbetween a spaced apart relationship (FIG. 10) and close cooperativealignment (not shown). The first jaw 20 includes a number of rows andeach row includes a plurality of staple forming depressions 24 (FIG.13). The second jaw 40 has opposed sidewalls 42, 44 that define achannel 46 with a generally U-shaped configuration extending between aproximal end of the second jaw 40 and a distal end of the second jaw 40(FIG. 12). The channel 46 is configured for releasably receiving astaple cartridge 63 that will be described in further detail below. Adistal portion of the channel 46 includes recesses 48 disposed onopposing interior surfaces of the channel 46 (FIG. 12). Additionally,the second jaw 40 has notches 41 near its distal end (FIG. 12).Specifically, each notch 41 is generally U-shaped and open at the topfor slidably receiving tabs 61 of the staple cartridge 63 as will belater described in further detail. A sloped surface 45 is formed at thedistal end of the second jaw member 40 (FIG. 12). The sloped surface 45extends from the external bottom surface of the jaw member 40 and leadsangularly to the interior surface of the jaw member 40.

With initial reference to FIGS. 1-3, a replaceable loading unit orcartridge assembly 60 for a surgical stapler, according to the presentdisclosure, is shown. The cartridge assembly 60 includes a staplecartridge 63 and a shipping wedge 80. The staple cartridge 63 includesretention slots 66 (FIG. 5) for receiving a plurality of staples orfasteners 50 and pushers 58 (FIG. 7). A plurality of laterally spacedapart longitudinal slots extends through the staple cartridge 63 foraccommodating upstanding cam wedges of an actuation sled 56 (FIG. 4). Acentral longitudinal slot extends along substantially the length ofstaple cartridge 63 and facilitates passage of a drive mechanism (notshown) having an actuation member. The actuation member is advanced by afiring rod and the actuation member abuts the actuation sled 56 andtranslates the actuation sled 56 through the longitudinal slots of thestaple cartridge 63, which advances the cam wedges into sequentialcontact with the pushers 58. The pushers 58 translate vertically alongthe cam wedges within the fastener retention slots 66 and urge thefasteners 50 from the retention slots 66 into staple forming depressions24 (FIG. 13) of the first jaw 20.

The staple cartridge 63 has an elongated body portion that houses aplurality of surgical staples 50 and a plurality of pushers 58 forejecting the surgical staples 50 from the staple cartridge 63 throughopenings 67 of the retention slots 66 towards the staple formingdepressions 24 on the first jaw 20. The openings 67 extend through atissue contacting surface 64 of the staple cartridge 63. The tissuecontacting surface 64 includes surfaces 64 a, 64 b, and 64 c, forming astepped shape. As illustrated in FIG. 7, surfaces 64 a are locatedadjacent a knife slot 53 (FIG. 5) that extends from a proximal portionof the staple cartridge 63 to a distal portion of the staple cartridge60 and is configured for slidably guiding a knife 51 (FIG. 4). Surfaces64 b are positioned adjacent surfaces 64 a with surfaces 64 c furthestaway from the knife slot 53. The surfaces 64 a, 64 b, and 64 c aresubstantially parallel to one another, but they are located in differentplanes thereby defining a stepped configuration as seen in FIGS. 7-9.Surfaces 64 a are substantially aligned with each other in a firstcommon plane, surfaces 64 b are substantially aligned with each other ina second common plane, and surfaces 64 c are substantially aligned witheach other in a third common plane. The staple cartridge 63 isconfigured for releasable attachment to the second jaw 40. The elongatedbody portion of the staple cartridge 63 has an open proximal end foroperatively engaging the drive mechanism of the surgical stapling device10, 10′ and a contoured nose 52 disposed at the distal end of the staplecartridge 63 for bluntly engaging body tissue. In particular, the nose52 has an angled recess 54 disposed on a bottom surface of the nose 52(FIG. 2). The angled recess 54 of the nose 52 is substantially alignedwith the sloped surface 45 of the second jaw member 40 (FIG. 12),thereby defining a gap 34 for receiving a tongue 90 located at a distalend of a shipping wedge 80 (FIGS. 14-16). Each sidewall of the staplecartridge 63 includes an outwardly extending ridge or rail 68, whichextends along a major length of each sidewall starting at a distal endof the staple cartridge 63.

In any of the embodiments disclosed herein, the cartridge assembly 60can include an actuation member with a knife 51, an upper portion forengaging the anvil assembly, and a lower portion for engaging the jawmember 40. An example of such an actuation member is disclosed in U.S.application Ser. No. 13/280,880, the disclosure of which is herebyincorporated by reference herein in its entirety.

Referring to FIGS. 11-13, the staple cartridge 63 includes opposingprotrusions 62 near its distal end. The protrusions 62 are configuredfor frictionally engaging the recesses 48 of the channel 46. Once thestaple cartridge 63 is aligned in the channel 46, additional movement ofthe staple cartridge 63 towards a bottom surface 47 of the channel 46causes positive engagement of the protrusions 62 and the correspondingrecesses 48. Once the staple cartridge 63 is fully seated in the channel46, the frictional engagement between the protrusions 62 and therecesses 48 maintain the staple cartridge 63 in operational engagementwith the channel 46 and the second jaw 40. Further, the staple cartridge63 includes tabs 61 (FIG. 5) extending from opposite sidewalls of thestaple cartridge 63. The tabs 61 are adapted for slidable engagement inthe notches 41 of the second jaw 40. When tabs 61 are positioned in thenotches 41, the staple cartridge 63 is properly aligned with the channel46 of the second jaw 40.

Referring to FIGS. 2, 3, 5, and 6, the shipping wedge 80 is releasablyattached to the staple cartridge 63. In particular, the shipping wedge80 is an elongated structure having opposing proximal and distal endswith the tongue 90 extending distally from the distal end. The shippingwedge 80 also includes opposed top and bottom surfaces 82, 84 with thebottom surface 84 configured for contacting the tissue contactingsurface 64 of the staple cartridge 63. The shipping wedge 80 has a widththat is greater than a width of the staple cartridge 63. A plurality oftabs 83 are disposed on side edges of the shipping wedge 80 and each tab83 extends in a direction that is transverse to the bottom surface 84 ofthe shipping wedge 80. Each tab 83 has a generally planar outsidesurface 85, a generally planar bottom surface 81, and an inner surface87 with a rounded protrusion 89 opposite the generally planar outsidesurface 85. Each tab 83 has resilience in that it is bendable withrespect to the bottom surface 84 of the shipping wedge 80 and is biasedtowards a neutral or initial position that is substantially transverseto the bottom surface 84 of the shipping wedge 80. Additionally, theshipping wedge 80 includes a central keel 94 that extends along a majorportion of the bottom surface 84 of the shipping wedge 80. The keel 94is configured for positioning in the knife slot 53 of the staplecartridge 63. The shipping wedge 80 and the staple cartridge 63 arereleasably attached to each other as described below.

As best illustrated in FIG. 5, the shipping wedge 80 is initiallyseparated from the staple cartridge 63 and oriented such that the bottomsurface 84 of the shipping wedge 80 is in opposition with the tissuecontacting surface 64 of the staple cartridge 63. As the shipping wedge80 is advanced into engagement with the staple cartridge 63, the tabs 83of the shipping wedge 80 engage the rails 68 of the staple cartridge 63.The resiliency of the tabs 83 allows them to flex outwardly and awayfrom the longitudinal axis of the shipping wedge 80 as the shippingwedge 80 is attached to the staple cartridge 63. This is assisted by thecurvate configuration of the protrusion 89 on the inner surface 87 ofthe tab 83. With the bottom surface of the shipping wedge 84 in contactwith the tissue contacting surface 64 of the staple cartridge 63, thecurvate protrusions 89 of the tabs 83 are no longer in contact with therails 68 of the staple cartridge 63. In particular, as seen in FIG. 7,the configuration of the rails 68 and the tabs 83 of the shipping wedge80 is such that when the shipping wedge 80 is seated on the tissuecontacting surface 64 of the staple cartridge 63, the curvate protrusion89 of each tab 83 has traversed beyond the rail 68. Since each tab 83 isresiliently biased towards the neutral position, when the curvateprotrusion 89 has traversed beyond the rail, the tab 83 returns to itsneutral position aided by the resiliency of the tab and an upper portionof the curvate protrusion 89 engages an edge of the rail 68 and holdsthe shipping wedge 80 in place with the staple cartridge 63. The centralkeel 94, in cooperation with the knife slot 53, acts to align theshipping wedge 80 with the staple cartridge 63. Further still, when theshipping wedge 80 is attached to the staple cartridge, the bottomsurface 84 of the shipping wedge 80 abuts the tissue contacting surface64 of the staple cartridge 63 and maintains the surgical staples 50 intheir respective retention slots 66. Further still, the bottom surface84 of the shipping wedge 80 has a complementary configuration to that ofthe tissue contacting surface 64 of the staple cartridge 63. Forexample, the bottom surface 84 of the shipping wedge 80 may have astepped shape to correspond to the stepped shape of the tissuecontacting surface. The shipping wedge 80 may also maintain a uniformdistance between the first and second jaws 20, 40 when the jaws 20, 40are in close cooperative alignment.

Referring now to FIG. 10, the first and second jaws 20, 40 are spacedapart and the shipping wedge 80 has been separated from the staplecartridge 63 of the cartridge assembly 60. In particular, the shippingwedge 80 is positioned such that the tongue 90 is inserted into the gap34 between the staple cartridge 63 and the channel 46 of the second jaw40. With additional reference to FIGS. 14-18, removal of the staplecartridge 63 from the second jaw 40 will now be described. The shippingwedge 80 is oriented such that the top surface 82 of the shipping wedge80 is facing the same direction as the bottom surface 47 of the secondjaw 40 of the end effector 100. With this arrangement, the tongue 90 ofthe shipping wedge 80 is readily insertable into the gap 34 between thestaple cartridge 63 and the second jaw 40 as shown in FIGS. 15-18. Withthe tongue 90 of the shipping wedge 80 disposed in the gap 34 betweenthe staple cartridge 60 and the second jaw 40, the shipping wedge 80 ismanipulated relative to the second jaw 40, as shown in FIGS. 19 and 20.For example, the shipping wedge 80 is pivoted with a distal tip of thetongue 90 acting as a pivot point for the shipping wedge 80. As theshipping wedge 80 is pivoted relative to the second jaw 40, contactbetween a bottom surface of the tongue 90 and a distal portion of thestaple cartridge 63 applies sufficient force and overcomes thefrictional engagement between the protrusions 62 of the staple cartridge63 and the recesses 48 of the channel 46 of the second jaw 40. Thus, thestaple cartridge 63 is separated from the channel 46 of the second jaw40 as shown in FIGS. 19 and 20. After the staple cartridge 63 isseparated from the channel 46 of the second jaw 40, a replacementcartridge may be inserted into the channel 46 and operatively coupled tothe surgical instrument.

The shipping wedge 80 maintains the staples in the cartridge assembly60, and facilitates the removal of the cartridge assembly 60 from thesecond jaw 40 while minimizing the user's potential contact with theknife 51. Furthermore, in any of the embodiments disclosed herein, theshipping wedge 80 can be configured to shield or cover the blade of theknife 51 or some other portion of the actuation member.

With reference to FIGS. 6A and 6B, additional embodiments of theshipping wedge are disclosed. Each shipping wedge is substantiallysimilar to shipping wedge 80 and only the differences are discussed indetail. FIG. 6A illustrates a shipping wedge 80 a including a centralkeel 94 a that extends along a major portion of a bottom surface 84 a ofshipping wedge 80 b. Central keel 94 a has side surfaces 95 a. Each sidesurface 95 a includes a plurality of curved protrusions 89 a. Whenshipping wedge 80 a is attached to staple cartridge 60, the plurality ofcurved protrusions 89 a cooperate with knife slot 53 to align shippingwedge 80 a with staple cartridge 63 and attach shipping wedge 80 a tostaple cartridge 63 with a friction fit. The plurality of curvedprotrusions 89 a can align shipping wedge 80 a longitudinally and/orcentrally with staple cartridge 63.

Now referring to FIG. 6B, a shipping wedge 80 b includes a central keel94 b that extends along a major portion of a bottom surface 84 b ofshipping wedge 80 b. Central keel 94 b includes side surfaces 95 bforming a wave pattern about the longitudinal axis. The wave pattern hasa plurality of crests or curved protrusions 89 b. When shipping wedge 80b is attached to staple cartridge 60, the plurality of curvedprotrusions 89 b cooperate with knife slot 53 to align shipping wedge 80b with staple cartridge 63 and attach shipping wedge 80 b to staplecartridge 63 with a friction fit. The plurality of curved protrusions 89b can align shipping wedge 80 b longitudinally and/or centrally withstaple cartridge 63.

Referring now to FIG. 22, a manually operated surgical stapling device10 is disclosed, an example of such a device is disclosed in U.S. Pat.No. 7,565,993 the entire contents of which is hereby incorporated byreference. Briefly, manually operated surgical stapling device 10includes a handle assembly 112 and an elongated body 114. A disposableloading unit or DLU 32 is releasably secured to a distal end ofelongated body 114. Disposable loading unit 32 includes an end effector100 having a first jaw 20 and a second jaw 40. The second jaw 40 isconfigured to releasably receive a staple cartridge 63 of a cartridgeassembly 60, as described above. Handle assembly 112 includes astationary handle member 122, a movable handle member 124, and a barrelportion 126. Handle assembly 112 actuates a drive mechanism (not shown)having a firing rod that advances the actuation member abutting theactuation sled 56 (FIG. 4), as discussed above, when the moveable handlemember 124 is moved towards the stationary handle member 122. Handleassembly 112 may also actuate first and second jaws 20, 40 from thespaced apart relationship to the close cooperative alignment.

FIG. 23 illustrates an exemplary embodiment of a powered or motorizedsurgical stapling device 10′, an example of such a device is disclosedin U.S. patent application Ser. No. 13/331,047 the disclosure of whichis hereby incorporated by reference herein in its entirety. Poweredsurgical stapling device 10′ includes a handle 201, an adaptor 200, anda disposable loading unit 32′. Handle 201 includes a handle housing 202having a lower housing portion 204, an intermediate housing portion 206extending from and/or supported on lower housing portion 204, an upperhousing portion 208 extending from and/or supported on intermediatehousing portion 206, and a cavity (not shown) defined within. A drivemechanism (not shown) is situated within the cavity. The drive mechanismmay be disposed within the upper portion 208. A connecting portion 208 aof upper housing portion 208 is configured to accept a correspondingdrive coupling assembly 210 of adapter 200. An end effector couplingassembly 230 at the distal end of adaptor 200 is configured to receivethe proximal end of disposable loading unit 32′. When adapter 200 ismated to handle 201 and disposable loading unit 32′, the drive mechanismengages a firing rod that advances the actuation member abutting theactuation sled 56 (FIG. 4), as discussed above, when a button of buttonassembly 232 is depressed. Button assembly 232 may also include a buttonthat actuates first and second jaws 20, 40 from the spaced apartrelationship to the close cooperative alignment.

In another aspect, a method of removing a staple cartridge from astapling instrument includes separating a shipping wedge from a staplecartridge, inserting a distal end of the shipping wedge into a gapbetween the staple cartridge and the stapling instrument, andmanipulating the shipping wedge to separate the staple cartridge fromthe stapling instrument. Any of the embodiments of the cartridgeassembly 60 including the staple cartridge 63 and the shipping wedge 80,80 a, 80 b and a surgical stapling device 10, 10′, disclosed herein, canbe used with the method.

The step of separating a shipping wedge may include grasping a tongue onthe distal end of the shipping wedge and grasping a nose on the distalend of the staple cartridge and pulling the tongue and the nose inopposing directions. The shipping wedge and staple cartridge may be partof a cartridge assembly. The stapling instrument may include a jaw andthe gap may be defined between the staple cartridge and the jaw. Thestep of inserting may include inserting the tongue into the gap.Manipulating the shipping wedge may include pivoting the shipping wedgewith respect to the gap, thus overcoming the frictional engagementbetween the staple cartridge and the stapling instrument.

In a further aspect, a method of replacing a staple cartridge of astapling instrument is disclosed. The method includes removing thestaple cartridge from a stapling instrument and replacing the staplecartridge with a new or unfired cartridge assembly. The method includesthe steps of separating a shipping wedge from a staple cartridge,inserting a distal end of the shipping wedge into a gap, manipulatingthe shipping wedge to separate the staple cartridge from the staplinginstrument, and inserting an unfired staple cartridge into the staplinginstrument. The method may include any of the embodiments of thecartridge assembly 60 including the staple cartridge 63 and the shippingwedge 80, 80 a, 80 b and a surgical stapling device 10, 10′. The methodmay also include any of the embodiments of the method for removing astaple cartridge from a stapling instrument disclosed herein.

In some embodiments, the unfired staple cartridge includes an actuationmember with a knife.

It will be understood that various modifications may be made to theembodiments disclosed herein. Therefore, the above description shouldnot be construed as limiting, but merely as exemplifications ofparticular embodiments. Those skilled in the art will envision othermodifications within the scope and spirit of the claims appended hereto.

What is claimed is:
 1. A surgical instrument comprising: a first jawpivotably coupled to a second jaw, the second jaw having a channel; astaple cartridge positioned in the channel, the staple cartridge and thesecond jaw defining a gap therebetween; and a shipping wedge releasablyattached to the staple cartridge, the shipping wedge having a tongueextending from one end thereof, the tongue insertable into the gap whenthe staple cartridge is positioned in the channel such that manipulatingthe shipping wedge separates the staple cartridge from the second jaw.2. The surgical instrument of claim 1, wherein the tongue has a taperedconfiguration and the second jaw has a recess for receiving the tongue.3. The surgical instrument of claim 1, wherein the second jaw has agenerally U-shaped configuration with opposing sidewalls, each sidewalldefining a groove extending along a portion of its length, each grooveconfigured to receive a portion of the staple cartridge to secure thestaple cartridge within the channel.
 4. The surgical instrument of claim1, wherein the shipping wedge includes a plurality of tabs and thestaple cartridge including rails, each rail extending along a portion ofa length of the staple cartridge, each tab configured for releasablyengaging one of the rails of the staple cartridge.
 5. The surgicalinstrument of claim 1, wherein the shipping wedge maintains a uniformdistance between the first and second jaws when the jaws are in a closecooperative alignment.
 6. The surgical instrument of claim 1, whereinthe shipping wedge includes a keel disposed in a channel of the staplecartridge.
 7. The surgical instrument of claim 6, wherein the keelaligns the shipping wedge and the staple cartridge.
 8. The surgicalinstrument of claim 6, wherein the keel inhibits translation of anactuation member through the channel.
 9. The surgical instrument ofclaim 1, wherein the shipping wedge maintains surgical fasteners intheir respective retention slots.
 10. The surgical instrument of claim1, wherein the staple cartridge includes opposed sidewalls, eachsidewall having a knob extending therefrom, the knobs receivable inrecesses formed in a distal portion of the second jaw.
 11. The surgicalinstrument of claim 10, wherein the engagement of the knobs and therecesses maintains the staple cartridge in the second jaw.
 12. Thesurgical instrument of claim 1, wherein the gap is defined between adistal portion of the staple cartridge and a distal portion of thesecond jaw member.
 13. The surgical instrument of claim 1, wherein asloped surface is formed at a distal end of the second jaw member. 14.The surgical instrument of claim 13, wherein the sloped surface extendsfrom an external bottom surface of the second jaw member and leadsangularly to an interior surface of the second jaw member.
 15. Thesurgical instrument of claim 1, wherein the shipping wedge has a steppedshape.
 16. A method of removing a cartridge assembly from a staplinginstrument, comprising: separating a shipping wedge from a staplecartridge, the staple cartridge being part of a cartridge assemblyincluding a plurality of staples and staple pushers; inserting a distalend of the shipping wedge into a gap between the staple cartridge andthe stapling instrument when the staple cartridge is coupled to thestapling instrument; and manipulating the distal end of the shippingwedge within the gap to separate the staple cartridge from the staplinginstrument.
 17. The method according to claim 16, wherein inserting thedistal end of the shipping wedge into the gap includes inserting thedistal end of the shipping wedge between a jaw of the staplinginstrument and the staple cartridge.
 18. The method according to claim16, wherein inserting the distal end of the shipping wedge into the gapincludes inserting a tongue of the shipping wedge into the gap.
 19. Amethod of replacing a staple cartridge of a stapling instrument,comprising: separating a shipping wedge from a staple cartridge, thestaple cartridge and shipping wedge being part of a cartridge assemblyincluding a plurality of staples and staple pushers; inserting a distalend of the shipping wedge into a gap between the staple cartridge andthe stapling instrument when the staple cartridge is coupled to thestapling instrument; manipulating the distal end of the shipping wedgewithin the gap to separate the staple cartridge from the staplinginstrument; and replacing the staple cartridge with an unfired staplecartridge.
 20. The method according to claim 19, wherein the unfiredstaple cartridge includes an actuation member having a knife.